Honeywell Krom Schroder BCU 460 Technical Information
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Honeywell Krom Schroder BCU 460 Technical Information

Burner control units
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Burner control units BCU 460, BCU 465
• For burners in intermittent operation or in continuous operation
• Flame control by UV, ionization or a further option of using the furnace
chamber temperature
• Simple system integration using the PC programming and diagnostic
software BCSoft
• With optional valve proving system
• With optional operating modes to reduce thermal NO
• Fieldbus connection (PROFIBUS, PROFINET, EtherNet/IP) using
optional bus module
x
TECHNICAL INFORMATION
EN
06.20
03251605

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Summary of Contents for Honeywell Krom Schroder BCU 460

  • Page 1 Burner control units BCU 460, BCU 465 TECHNICAL INFORMATION • For burners in intermittent operation or in continuous operation • Flame control by UV, ionization or a further option of using the furnace chamber temperature • Simple system integration using the PC programming and diagnostic software BCSoft •...

  • Page 2: Table Of Contents

    Contents Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 4.1.1 BCU..F1 .
  • Page 3 10.4 Behaviour during start-up ....77 10.10.4 Proof of closure function test period ... . . 102 10.4.1 Burner 1 start-up attempts .
  • Page 4 12.2 Power module LM 400 ..... 118 16.2 Mechanical data ......132 12.2.1 Type code .
  • Page 5 Fore more information . . . . . . . . . . . . . . . . . . . . . . . . 144 BCU 460, BCU 465 ·...

  • Page 6: Application

    Application 1 Application burner control unit has an interface via which an air valve or actuator can be controlled for staged or modulating burner See also the video “Kromschröder BCU 4 Series – capacity control. Next-Generation Burner Control Unit” in DE, EN or CN. The program status, device parameters, error codes, sta- tistics and level of the flame signal can be read easily and conveniently on the four-digit device display.
  • Page 7 Application As an option, the BCU can be configured with high tem- perature operation and an operating mode for low NO emissions. In High temperature mode, the BCU can monitor the flame indirectly using the temperature. The Low mode leads to a significant reduction in thermal NO formation in ON/OFF-controlled high-velocity burners due to its flame- less operation.

  • Page 8: Application Examples

    Application 1 . 1 Application examples 1 . 1 .2 PROFINET connection using bus module BCM 1 . 1 . 1 Single-stage-controlled burner L1, N, PE BCM..B2 = PROFINET BCM..B4 = Modbus TCP Start 1 µC The bus system transfers the control signals from the auto- BCU 465..F3 mation system (PLC) to the BCU/BCM for starting, resetting, 65 36...

  • Page 9: Staged Control

    Application 1 . 1 .3 Staged control application “Burner 1 with pilot gas” (parameter A078 = 1) is selected so that the burner can be started with a limited Process control (PCC) start fuel flow rate. FCU 500 To activate the high-fire rate, DI 2 is actuated via the air valve output at terminal 66 of the BCU.

  • Page 10: Modulating Control With Defined Ignition Position

    Application 1 . 1 .4 Modulating control with defined ignition dition: the IC 40 must have reached the ignition position on position the instant of ignition). The burner starts. The burner application “Burner 1 with pilot gas” (parameter Process control (PCC) A078 = 1) is selected so that the burner can be started with FCU 500 a limited start fuel flow rate.

  • Page 11: Two-Stage-Controlled Burner

    Application 1 . 1 .5 Two-stage-controlled burner 1 . 1 .6 Single-stage-controlled burner with pneumatic ratio control system Process control (PCC) FCU 500 L1, N, PE Start 1 6 35 Start 1 µC µC BCU 460 LM..F3 60 61 BCU 465..F3 60 61 VG..L...

  • Page 12: Flame Control Using The Temperature

    Application 1 . 1 .7 Flame control using the temperature If the furnace temperature falls below the spontaneous ignition temperature (< 750°C), the FCU disconnects the FCU 500..H1 HT output from the electrical power supply. There is no longer an active signal at the HT inputs of the burner control units.

  • Page 13: Flameless Mode To Reduce No Formation

    Application 1 . 1 .8 Flameless mode to reduce NO formation Switching to Low NO mode eliminates the counterpres- sure by the flame in the ceramic tube TSC. At a constant Process Control (PCC) gas supply pressure, the gas volume increases by approxi- mately 15%.

  • Page 14: On/Off Rotary Impulse Control

    Application 1 . 1 .9 ON/OFF rotary impulse control BCU 460/ LM..F3 VR..L µC BCU 460/ LM..F3 >750° FCU 500..F0 47 48 Purge VR..L For processes which require a turndown of more than 10:1 operating time to the pause time. In this type of control, the and/or those which require heavy circulation of the furnace burner output pulse frequency always maintains full mo- atmosphere to ensure a uniform temperature, e.g.
  • Page 15 Application thus maintains a constant air/gas ratio. At the same time, it acts as a low air pressure protection device. The ignition and monitoring of the individual burners is en- sured by burner control unit BCU 460 with power module LM..F3. The centrally checked safety functions such as pre-purge, tightness test, flow detector and pressure switch check (gas...

  • Page 16: Modulating Burner Control

    Application 1 . 1 . 1 0 Modulating burner control BCU 460..F0 µC BCU 460..F0 >750° FCU 500..F1 47 48 Purge The centrally checked safety functions such as pre-purge, To ensure that the correct air volume is available for ignition setting the valve to ignition position via a butterfly valve (start fuel flow rate) when starting the burners, the FCU control system, tightness test, flow detector and pressure...
  • Page 17 Application sures that the burners can only start if the safety interlocks and the LDS output have enabled burner start-up. BCU 460, BCU 465 · 06.20 · EN...

  • Page 18: Certification

    Certification 2 Certification Certificates – see www.docuthek.com Certified to SIL and PL For systems up to SIL 3 pursuant to EN 61508 and PL e pursuant to ISO 13849. See page 135 (Safety-specific characteristic values for SIL and PL). EU certified • 2014/35/EU (LVD), Low Voltage Directive •...

  • Page 19: Function

    Function 3 Function Use the ON/OFF key to switch the control unit on or off. 3 . 1 Part designations The control unit is reset to its starting position in the event of a fault using the Reset/Information button. During operation, the LED display shows the program status.

  • Page 20: Connection Diagram

    Function 3 .2 Connection diagram Electrical connection, see page 120 (Electrical connection) Explanation of symbols, see page 139 (Legend) 3 .2 . 1 BCU 460 . .E1/LM 400 . .F0 . .E1 with ionization control in double-electrode operation Alternative flame control, see page 26 (Flame control) Start 1 BCU 460 82 81 80...

  • Page 21: Bcu 460

    Function 3 .2 .2 BCU 460 . .E1/LM 400 . .F3 . .E1 with ionization Electrical connection, see page 120 (Electrical connection) control in double-electrode operation Explanation of symbols, see page 139 (Legend) Alternative flame control, see page 26 (Flame control) Start 1 BCU 460 82 81 80...

  • Page 22: Bcu 465

    Function 3 .2 .3 BCU 465 . .E1/LM 400 . .F3 . .E1 with ionization Electrical connection, see page 120 (Electrical connection) control in double-electrode operation Explanation of symbols, see page 139 (Legend) Alternative flame control, see page 26 (Flame control) Start 1 BCU 465 82 81 80...

  • Page 23: Bcu 460

    Function 3 .2 .4 BCU 460 . .P3 . .E1/LM 400 . .F0 . .E1 with industrial Electrical connection, see page 120 (Electrical connection) plug for ionization control in double-electrode Explanation of symbols, see page 139 (Legend) operation Alternative flame control, see page 26 (Flame control) 11 12 BCU 460 82 81 80...

  • Page 24: Bcu 460

    Function 3 .2 .5 BCU 460 . .P3 . .E1/LM 400 . .F3 . .E1 with industrial Electrical connection, see page 120 (Electrical connection) plug for ionization control in double-electrode Explanation of symbols, see page 139 (Legend) operation Alternative flame control, see page 26 (Flame control) 11 12 2 BCU 460 82 81 80...

  • Page 25: Bcu 465

    Function 3 .2 .6 BCU 465 . .P3 . .E1/LM 400 . .F3 . .E1 with industrial Electrical connection, see page 120 (Electrical connection) plug for ionization control in double-electrode Explanation of symbols, see page 139 (Legend) operation Alternative flame control, see page 26 (Flame control) 11 12 2 BCU 465 82 81 80...

  • Page 26: Flame Control

    Function 3 .2 .7 Flame control UVC control In the case of UV control, use Elster UV sensors for intermit- Parameter I004 = 2. tent operation (UVS 5, 10) or flame detectors for continuous operation (UVC 1). 51 21 Ionization control in single-electrode operation Parameter I004 = 0.

  • Page 27: Assignment Of Connection Terminals

    Function 3 .2 .8 Assignment of connection terminals Control input (AC mains voltage) Termi- Designation Function Start-up signal Signal applied: heating start; no signal: heating stop Input for external signal (button) to reset the unit after a fault lock-out. System faults (in- Remote reset ternal errors) can only be acknowledged using this button.
  • Page 28 Function Output Terminal Designation Function 52, 53 UV sensor Voltage supply for UV sensor UVS Voltage supply + safety circuit input (AC mains voltage) Terminal Designation Function UV sensor for continuous oper- 54, 24 Voltage supply for UV sensor UVC 1 ation 57, 27, 36 Minimum air pressure Connection for sensor 1 with pilot lamp to monitor the air pressure...
  • Page 29 Function Terminal Designation Function 85, 86, 87 Parameter-dependent function Contact can be adjusted depending on parameter I054 90, 91, 92 Parameter-dependent function Contact can be adjusted depending on parameter I051 BCU 460, BCU 465 · 06.20 · EN...

  • Page 30: Program Sequence

    Function 3 .3 Program sequence Operation signalling contact closes, valve for 2 gas stage opens and min. operating time t starts to elapse (A061) Switch on BCU 460 ▼ ▼ In the event of flame failure: In the event of fault signal: reset restart or fault lock-out ▼...

  • Page 31: Bcu 465 Program Sequence

    Function 3 .4 BCU 465 program sequence ▼ If parameter A048 = 1: Switch on BCU 465 air valve opens with 1 gas stage ▼ ▼ In the event of fault signal: reset If no flame detected: ▼ max. 3 start-up attempts (A007) or fault lock-out Safety interlocks ▼...

  • Page 32: Air Control

    Air control 4 Air control F1 = actuator IC 40, BCU with LM..F3 = valve) are actuated for this purpose by the capacity control system of the BCU. A central protective system such as the FCU 500 takes over After being enabled by the protective system, the BCU can air control.

  • Page 33: Capacity Control

    Air control 4 . 1 Capacity control control to approach the position for pre-purge. The pro- tective system (FCU 500) starts the pre-purge time if there 4 . 1 . 1 BCU . .F1 is adequate air flow. After the elapse of the pre-purge time, the control element moves to the ignition position.

  • Page 34: Bcu

    Air control 4 . 1 .2 BCU . .F3 ble signal, the burner can be started by the start-up signal at terminal 1. The gas valves for the 1 stage are opened Process control (PCC) and the burner is ignited (on the BCU..C1 after a successful FCU 500 valve check).

  • Page 35: Low No Mode (Flameless Operation)

    Low NOx mode (flameless operation) 5 Low NO mode (flameless operation) The gas and air for Flame mode and Low NO mode are supplied via the same connections. The gas pressure up- Low NO mode leads to a significant reduction in thermal stream of the burner is adjusted using a pressure regulator formation in ON/OFF-controlled high-velocity burners.
  • Page 36 Low NOx mode (flameless operation) Flame mode action zone is considerably larger and the reaction density considerably lower. This prevents the occurrence of peak In order to heat up the furnace, the burner operates in temperatures which are responsible for high NO values.

  • Page 37: Bcu

    Low NOx mode (flameless operation) 5 .2 BCU . .D2 Parameter settings for switching between Flame mode and Flameless mode, see page 78 (Burner application), page The BCU coordinates the signals for starting the burner 94 (Pre-ventilation/flameless), page 96 (Combustion and the fail-safe monitoring of the burner in Flame mode.

  • Page 38: Valve Proving System

    Valve proving system 6 Valve proving system 6 . 1 Tightness control The BCU 500..C1 is fitted with an integrated valve proving The aim of the tightness control is to identify an inadmissible system. This allows either the tightness of the gas solenoid leak on one of the gas solenoid valves and to prevent burn- valves and the pipework between them to be checked or er start.

  • Page 39: Test Instant

    Valve proving system 6 . 1 . 1 Test instant test volume V can be vented during the tightness test with the air/gas ratio control closed. Depending on the parameter setting, the tightness control checks the tightness of the pipework and the gas solenoid valves before each start-up and/or after each shut-down of the burner, see page 98 (Valve proving system).

  • Page 40: Program Sequence

    Valve proving system 6 . 1 .2 Program sequence The tightness test starts by checking the external pressure switch. START If pressure p > p /2, program A starts. If pressure p < p /2, program B starts. Program A Program B –...
  • Page 41 Valve proving system During the measurement time t , the tightness control checks the pressure p between the valves. If pressure p < p /2, valve V2 is leaking. If pressure p > p /2, valve V2 is tight. The tightness test can only be performed if pressure p downstream of V2 is around atmospheric pressure and the volume downstream of V2 is at least 5 ×...

  • Page 42: Test Period T P

    Valve proving system 6 . 1 .3 Test period t Depending on the burner capacity, the tightness of the gas solenoid valves must be checked in accordance with the relevant application standard, e.g. EN 676, EN 746, NF- PA 85 and NFPA 86. The test period t is calculated from: •...

  • Page 43: Measurement Time T

    Valve proving system 6 . 1 .5 Measurement time t The sensitivity of the tightness control in the BCU can be adjusted for each individual system by adapting the meas- urement time t . The longer the measurement time t , the greater the sensitivity of the tightness control.
  • Page 44 Valve proving system Test volume V Valves Pipe Test volume V is calculated from the valve volume V Volume per metre Type Volume V [l/m] added to the volume of the pipe V for each additional me- VK 100 tre in length L. VK 125 13.6 VK 150...
  • Page 45 Valve proving system Calculation examples 2 valves VAS 665, distance L = 9.5 m, inlet pressure p = 50 mbar, max. flow rate Q = 200 m (N)max. VAS 665 VAS 665 (N) max. 200 m = 50 mbar 9.5 m DN65 µC >750° 47 48 Leakage rate Q = 200 m...

  • Page 46: Proof Of Closure Function

    Valve proving system 6 .2 Proof of closure function PA 85 (Boiler and Combustion Systems Hazards Code) and NFPA 86 (Standard for Ovens and Furnaces). The proof of closure function monitors the function of a gas solenoid valve (V1, V2, V3 or V4). A limit switch on the gas Program sequence solenoid valve signals the closed position of the valve to the When the start-up signal is received at terminal 1, the BCU...

  • Page 47: Bcsoft

    BCSoft 7 BCSoft BCSoft is an engineering tool for PCs with a Windows oper- ating system. BCSoft (from version 4.x.x) makes it possible to set device parameters in order to adjust them to the specific application. BCSoft logs and archives the device parameters.

  • Page 48: Fieldbus Communication

    Fieldbus communication 8 Fieldbus communication PROFIBUS DP, PROFINET and EtherNet/IP are manufac- turer-independent, open standards for industrial network communication. They cover the requirements for automa- tion technology (manufacturing automation, process auto- mation, drive applications without functional safety). They are bus variants for fieldbus communication optimized for speed and low connection costs.

  • Page 49: Bcu And Bus Module Bcm

    Fieldbus communication 8 . 1 BCU and bus module BCM Safety-related signals and interlocks (e.g. safety interlock) must be wired independently of the fieldbus communica- The optional bus module BCM 400 is required to integrate tion direct between the BCU and the protective system the BCU in a standardized fieldbus system (PROFIBUS, (e.g. FCU).

  • Page 50: Configuration, Planning

    Fieldbus communication 8 .2 Configuration, planning Before commissioning, the bus module must be configured for data exchange with the fieldbus system using an engi- neering tool or BCSoft. To do so, fieldbus communication must be enabled on the control unit with connected bus module BCM and the code switches on the BCM set, see also page 103 (Fieldbus communication).

  • Page 51: Profinet, Ethernet/Ip

    Fieldbus communication 8 .3 PROFINET, EtherNet/IP In addition to cyclic data exchange, the PROFINET and EtherNet/IP fieldbus systems also provide acyclic data ex- change for events which are not constantly repeated, such as sending device statistics. In the event that the bus com- munication is faulty or interrupted and during initialization of the bus communication after switching on, the digital signals are interpreted as “0”.
  • Page 52 Fieldbus communication Inputs/Outputs Byte n Byte n+1 Format The digital input and output signals from the burner control External air ON Cooling air valve BOOL unit BCU are included in this module. Pre-purge ON Free BOOL Burner 2 start Free BOOL Input bytes (BCU ➔...
  • Page 53 Fieldbus communication Burner 1 flame signal (BCU ➔ PLC) Every status signal is allocated a code. The allocation is described in the code table “BusCommunication_BCU4_ The flame signal for burner 1 is transferred from the BCU to R2.xlsx”. the PLC as an analogue value using this module. The flame signal occupies one byte with values from 0 to 255 (= flame Data Byte n...
  • Page 54 Fieldbus communication Fault and warning signals (BCU ➔ PLC) Remaining times (BCU ➔ PLC) The fault and warning signals are transferred from the BCU This module transfers the remaining times of various pro- to the PLC using this module. The fault and warning signals cesses from the BCU to the PLC.
  • Page 55 Fieldbus communication BCU input information (BCU ➔ PLC) This module transfers the signal states of the digital inputs on the BCU to the PLC. Transfer via Input terminals K-SafetyLink NFS bus Byte n Byte n+1 Byte n+2 Byte n+3 Byte n+4 Format Safety interlocks Terminal 1...

  • Page 56: Device Parameters And Statistics

    Fieldbus communication 8 .3 .2 Device parameters and statistics With the help of acyclic communication between the PLC and BCU, it is possible to read information on parameters, statistics and fault history on an event basis (e.g. using sys- tem function block Siemens FSB 52 RDREC). PROF- EtherNet/IP INET...

  • Page 57: Profibus

    Fieldbus communication 8 .4 PROFIBUS Inputs Outputs 460/465 basic I/O 1 byte 1 byte Input bytes (BCU ➔ master) 460/465 standard 4 bytes 1 byte Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Burner 1 op- Free Free Baud rate: up to 1500 kbit/s.

  • Page 58: Program Step/Status

    Program step/status 9 Program step/status DISPLAY Program step/status Start-up position/Standby Cooling Pre-purge (external) Delay Minimum pause time t Pre-ventilation “No flow” state check of low air pressure protection device Low air pressure protection check Approaching minimum capacity/closed position Approaching maximum capacity Pre-purge (internal) Approaching ignition capacity Delay (in program step X)
  • Page 59 Program step/status DISPLAY Fault message (flashing) Description No flame after safety time 1 E 02 No flame formation to end of 1 safety time E 03 Flame failure during flame proving period 1 t Flame failure during burner 1 operation E 04 Flame failure during operation Too many remote resets E 10...
  • Page 60 Program step/status DISPLAY Fault message (flashing) Description Internal error E 89 Error in processing internal data E 91 Flame amplifier or fuses defective Check the wiring and fuses Direct voltage is connected or signal inputs and L are E 92 Irregularities in the power supply connected to different phases Internal error...
  • Page 61 Program step/status DISPLAY Fault message (flashing) Description Controller in STOP position Controller in STOP position E A1 Burner 1 flame simulation Burner 1 flame simulation while air actuator is open No flame during safety time 1 while air actuator is E A2 No flame after safety time 1 open...

  • Page 62: Parameter

    Parameter 10 Parameter 10 . 1 Application parameters Any changes to parameters will be saved to the parameter chip card. Factory Name Parameter Value range default settings 2–20 μA where I004 = 0, 2–20 = Burner 1 flame signal switch-off threshold in μA 5–20 μA where page 72 (Burner 1 flame signal FS1 A001...
  • Page 63 Parameter Factory Name Parameter Value range default settings page 88 (Pre-ventilation time tVL) A036 0–250 = Time in seconds page 89 (Over-run time tNL) A039 0–60 = Time in seconds 0 = Off; checking the positions for minimum/maximum capacity 1 = On; for approaching the positions for minimum/maximum page 89 (Running time selection) A041 capacity...
  • Page 64 Parameter Factory Name Parameter Value range default settings page 84 (Minimum operating time A061 0–250 = Time in seconds page 100 (Minimum pause time A062 0–3600 = Time in seconds tMP) 0 = Upon next burner start page 95 (Flameless operation) A064 1 = Immediately 2 = Direct switchover...
  • Page 65 Parameter Factory Name Parameter Value range default settings 0 = Off 1 = Via fail-safe bus (K-SafetyLink) page 104 (Purge (bus)) A087 2 = Via terminal 3 = Via non-fail-safe bus 4 = Via fail-safe bus (K-SafetyLink) or terminal 0 = Off page 104 (High temperature opera- 1 = Via fail-safe bus (K-SafetyLink A088...
  • Page 66 Parameter Factory Name Parameter Value range default settings 0 = No function 1 = APS Purge 2 = APS Stage 1 3 = APS Purge & Stage 1 4 = APS Stage 2 5 = APS Purge & Stage 2 6 = APS Stage 1 &...

  • Page 67: Interface Parameters

    Parameter Factory Name Parameter Value range default settings page 97 (Over-run time, flameless A139 0–60 = Time in seconds tNL) 10 .2 Interface parameters Factory Name Parameter Value range default settings 0 = Ionization 1 = UVS sensor 2 = UVC sensor 3 = Ionization control for burner 1 and UVS control for burner 2 page 105 (Flame control) I004...
  • Page 68 Parameter Factory Name Parameter Value range default settings 0 = Off 1 = Ready signal 2 = Air signal page 110 (Contact 90, 91/92 func- 3 = Purge signal I051* tion) 4 = Cooling air valve 5 = Flue gas valve 6 = Fault signal 7 = Burner 1 operating signal 0 = Off...
  • Page 69 Parameter Factory Name Parameter Value range default settings 0 = Off 4 = Safety interlocks 5 = Air 6 = Cooling air 7 = Air actuator R1 8 = Air actuator R2 page 111 (Function of input 1) I061* 9 = Start 1 11 = Reset 12 = Purge 13 = LDS start-up conditions...
  • Page 70 Parameter Factory Name Parameter Value range default settings (on BCU 460) page 112 (Function of input 37) I070* See I069 (on BCU 465) (on BCU 460) page 113 (Function of input 38) I071* See I069 (on BCU 465) page 113 (Function of input 39) I072* See I061 page 113 (Function of input 40)

  • Page 71: Scanning The Parameters

    Parameter 10 .3 Scanning the parameters During operation, the four-digit 7-segment display shows the program step/status. In addition to the flame signal and the fault history, all the parameters of the BCU can be scanned in numerical order by repeatedly pressing the Reset/Information button (for 1 s).

  • Page 72: Flame Control

    Parameter 10 .3 . 1 Flame control ation after the elapse of the safety time during operation (parameter A019). The BCU is fitted with two OR-linked flame amplifiers, each of which evaluates whether an adequate flame signal is In the case of UV control, this value can be increased, supplied by the burner to the flame amplifier using a flame should the burner to be monitored be influenced by other rod or UV sensor.

  • Page 73: Flame Simulation Check In Standby Position

    Parameter 10 .3 .4 Flame simulation check in standby position Parameter A003 This defines the instant for the flame simulation check. Start 1 Parameter A003 = 0: flame simulation check in standby position. The flame simulation check is conducted provided Flame simulation check on start-up (parameter A003 = 1): no start-up signal (start 1) is applied (during the so-called start-up position/standby).

  • Page 74: High Temperature Operation

    Parameter 10 .3 .5 High temperature operation FCU 500..H1 Parameter A006 Operation of firing systems above 750°C. The BCU..D1 and BCU..D2 have a fail-safe input with the function “High tem- perature operation”. If firing systems are operated above BCU 46x..D1 750°C, the system is considered to be an item of high µC temperature equipment (see EN 746-2).
  • Page 75 Parameter in the event of sensor discontinuity or short-circuit, failure of the safety temperature monitor or power failure. The voltage may be applied to the HT input (terminal 6) so as to activate High temperature operation only when the temperature at the furnace wall has exceeded 750°C. The burner remains in operation and the BCU performs flame control again (recommended in the case of ionization control or UV control with UVC).
  • Page 76 Parameter Parameter A006 = 6: intermittent operation with UVS (only with BCU..D1). The BCU switches off the burner and restarts with flame simulation check (recommended in the case of UV control with UVS). If no flame signal is present when High temperature mode is deactivated, the burner control unit performs a fault lock- out, regardless of parameter A006.

  • Page 77: Behaviour During Start-Up

    Parameter 10 .4 Behaviour during start-up Parameter A007 = 2, 3: 2 or 3 start-up attempts. 10 .4 . 1 Burner 1 start-up attempts This parameter defines the maximum number of possible start-up attempts of burner 1. Taking into account national standards and require- ments, it must be clarified whether multiple start-up attempts are permitted .

  • Page 78: Burner Application

    Parameter 10 .4 .2 Burner application capacity. After the elapse of the flame proving period t (program step 04), it is closed again. Parameter A078 For this application, it must be ensured that the flame prov- This parameter enables the BCU to be adjusted to various ing period (parameter A095) is set to a value ≥ 2 s.
  • Page 79 Parameter Parameter A078 = 4: two-stage burner 1. Three valves (V1, V2 and V3) are included for a two-stage burner. These are connected to the valve outputs (terminals 60, 61 and 62). 6162 Valves V1 and V3 open to start the burner. The burner is started with a limited ignition capacity using gas valve V3.
  • Page 80 Parameter Parameter A078 = 13: Flameless 1/0 with 2 gas paths. On/ Off burner operation with different gas paths in Flame mode and Flameless mode. Process Control (PCC) BCU 465..F3 µC VR..N In Flame mode (< 850°C), the burner is started conven- tionally with the pre-ventilation time t defined in parame- ter A036.
  • Page 81 Parameter The switchover from Flame mode to Flameless mode is performed either immediately or the next time the burner is started depending on the setting made in parameter A064. To switch to Flameless mode, the HT signal from the STM (terminal 6) and the signal for Flameless mode must be sup- plied to the BCU by a separate control unit (terminal 7).

  • Page 82: Sa1

    Parameter 10 .4 .3 Safety time 1 t Flame proving period 1 (t ) can be parameterized to enable the flame on burner 1 to stabilize after the elapse Parameter A094 of safety time 1. Only when the flame proving period has During safety time 1 t , the flame (pilot flame) is ignited.

  • Page 83: Behaviour During Operation

    Parameter 10 .5 Behaviour during operation 10 .5 . 1 Restart Parameter A009 Restart can be programmed for burners which occasionally display unstable behaviour during operation. This parameter determines whether the BCU initiates an im- mediate fault lock-out or an automatic restart after a safety shut-down during operation.

  • Page 84: Minimum Operating Time T

    Parameter Parameter A009 = 1: burner 1. The restart function is active. 10 .5 .2 Minimum operating time t Parameter A061 A minimum operating time (0 to 250 s) may be defined to ensure that the heating equipment operates stably. If the minimum operating time is active, burner operation will be maintained until the set time has elapsed even if the start-up signal fails.

  • Page 85: Auxiliary Gas Function

    Parameter 10 .5 .3 Auxiliary gas function Parameter A077 One of the inputs at terminals 1 to 7 or 35 to 41 must be parameterized to the auxiliary gas function (parameter I061, I062 ... or I074 = 19). As soon as there is a signal at the input at terminal 1 to 7 or 35 to 41 and the BCU is operating (display 04), valve V4 (ter- minal 63) is opened depending on parameter A077.

  • Page 86: Safety Limits

    Parameter 10 .6 Safety limits Parameter A016 = 0: Off. Air pressure monitoring takes place immediately. The gas is only released when the signal Parameters A016 and A019 can be used to adjust the safe- is received from the air pressure switch. Parameter A048 ty limits (low air pressure protection and safety time during (Air actuator control) must be set to 1 for this function (air operation) to the system requirements.

  • Page 87: Safety Time During Operation

    Parameter 10 .6 .2 Safety time during operation Parameter A019 Parameter A019 = 0; 1; 2; 3; 4: time in seconds The safety time during operation is the time that the BCU needs to stop the fuel supply after a flame failure during op- eration or an interruption at the safety current inputs (termi- nals 36, 37 and 38).

  • Page 88: Air Control

    Parameter 10 .7 Air control 10 .7 . 1 Pre-purge time t Parameter A034 A burner start may only occur if it has been ensured that the concentration of inflammable components in all sec- tions of the combustion chamber and the connected areas as well as the flue gas ducts is less than 25% of the lower flammability limit of the fuel gas.

  • Page 89: Over-Run Time T Nl

    Parameter 10 .7 .3 Over-run time t Parameter A041 = 2: On; for approaching the position for maximum capacity. The running time set using parame- Parameter A039 ter A042 is activated for approaching the position for max- imum capacity, see page 90 (Running time). After this time has elapsed, the BCU will initiate the next program step.

  • Page 90: Running Time

    Parameter 10 .7 .5 Running time 10 .7 .6 Over-run Parameter A042 Parameter A043 This parameter can be used to adjust the behaviour in the The over-run (t ) supports applications with a pneumatic case of slow opening and closing air valves. The running air/gas ratio control system and On/Off control.
  • Page 91 Parameter A flame failure during the over-run does not result in a fault lock-out. Parameter A043 = 3: low fire over-run, time-bound. BCU 460..F3 µC VR..L The burners are initially powered down to low-fire rate and remain in operation for the programmed duration depend- ing on parameter A039 (in Flame mode) or A139 (in Flame- less mode).

  • Page 92: Air Actuator Control

    Parameter 10 .7 .7 Air actuator control Parameter A048 In cyclic operation, parameters A048 and A049 on BCU..F1 and F3 determine the behaviour of the air actuator during burner start and burner operation. The air actuator can be activated externally via the input at terminal 4 for cooling the burner in the start-up position (standby).

  • Page 93: Air Actuator On Start-Up Can Be Activated Externally

    Parameter 10 .7 .8 Air actuator on start-up can be activated 10 .7 .9 Air actuator in the event of fault externally Parameter A050 Parameter A049 This parameter decides whether the air actuator can be ac- Parameter A049 = 0: cannot be activated. tivated externally via the input at terminal 4 in the event of a fault lock-out.

  • Page 94: Pre-Ventilation/Flameless

    Parameter 10 .7 . 1 0 Pre-ventilation/flameless Parameter A028 This parameter is used to define the time during which the air valve is open in Flameless mode before the normal start- up. Suitable for burners starting with full air capacity. Adjustable from 0 to 250 s.

  • Page 95: Flameless Operation

    Parameter 10 .7 . 1 1 Flameless operation mediately. If the start-up signal continues to be applied, a burner start may be performed in Flame mode, depending Parameter A064 on the other parameters. As soon as there is a signal at the Flameless mode input (terminal 7), the BCU in High temperature mode can switch to Flame mode or Flameless mode immediately or upon the next burner start.

  • Page 96: Combustion Mode

    Parameter 10 .7 . 1 2 Combustion mode In Flame mode (< 850°C), the burner is started convention- ally (as with A078 = 0) with the pre-ventilation time t Parameter A074 fined in parameter A036. The air control valve is in the “high” The type of combustion in which the ignition takes place position for Flame mode.

  • Page 97: Over-Run Time, Flameless T Nl

    Parameter 10 .7 . 1 3 Over-run time, flameless t Parameter A139 In Flameless mode, the burner is started with the pre-ven- tilation time t defined in parameter A028. No ignition In Flameless mode, the actuator (air valve, actuator) will re- using the transformer takes place during the safety time t main open for the programmed over-run time t (0 to 60 s)

  • Page 98: Valve Check

    Parameter 10 .8 Valve check Parameter A052 = 2: V2. The valve on terminal 61 acts as the relief valve. 10 .8 . 1 Valve proving system Parameter A052 = 3: V3. The valve on terminal 62 acts as Parameter A051 the relief valve. Parameter A051 is used to define whether and at what time 10 .8 .3 Measurement time for V in the BCU program sequence the valve check is activated.

  • Page 99: Valve Opening Time T

    Parameter 10 .8 .4 Valve opening time t Parameter A059 This parameter is used to define the opening time for the valves (2 to 25 s) which are opened to fill or discharge the test volume between the gas valves. If the preset opening time t = 3 s is inadequate (e.g.

  • Page 100: Behaviour During Start-Up

    Parameter 10 .9 Behaviour during start-up If this function has been selected, operation of the burner may be continued manually in the event of failure of the 10 .9 . 1 Minimum pause time t control system or the bus activation. Parameter A062 Parameter A067 = 1: the BCU will terminate Manual mode 5 minutes after the last time the button is pressed.

  • Page 101: Sensors

    Parameter 10 . 1 0 Sensors Parameter A101 = 7: air pressure switch Purge & Stage 1 & Stage 2. The signal from the air pressure switch is evaluat- A sensor (pressure switch or POC switch) can be connect- ed during purging and if gas stages 1 and 2 are enabled. ed to each of the inputs at terminals 36, 37 or 38, see also Parameter A101 = 8: air pressure switch Flameless.

  • Page 102: Function Of Sensor 2

    Parameter Parameter A101 = 34: air pressure switch External High. 10 . 1 0 .2 Function of sensor 2 The signal from the air pressure switch is evaluated if the air Terminal 37 is assigned a sensor function using parameter actuator is activated externally during the High position.

  • Page 103: Communication

    Parameter 10 . 1 1 Communication Parameter 80 = 2: no address check. The device name/ network name can be selected as specified by the automa- 10 . 1 1 . 1 Fieldbus communication tion system. Parameter A080 10 . 1 1 .2 K-SafetyLink Fieldbus communication can be enabled using parame- Parameter A081 ter A080 when bus module BCM 400 is connected.

  • Page 104: Safety Interlocks (Bus)

    Parameter 10 . 1 1 .3 Safety interlocks (bus) Parameter A089 = 0: Off Parameter A085 Parameter A089 = 1: via fail-safe bus This parameter defines the interface through which the sig- Parameter A089 = 2: via terminal nal from the safety interlocks is received. Parameter A089 = 5: via fail-safe bus and terminal Parameter A085 = 1: via fail-safe bus Parameter A085 = 2: via terminal...

  • Page 105: Interface Parameters

    Parameter 10 . 1 2 Interface parameters The reaction times of the BCU and UV sensor for continu- ous operation are coordinated so that the set safety time Interface parameters I040 to I099 are set at the during operation (parameter A019) is not extended. factory and normally do not need to be adjusted .

  • Page 106: Air Actuator

    Parameter 10 . 1 2 .2 Air actuator position is not reached within the timeout time of 250 s, a safety shut-down of the BCU will be performed. A fault Parameter I020 message ( E Ac, E Ao or E Ai) will be displayed, see page Parameter I020 = 2: IC 40.
  • Page 107 Parameter Operating mode 11 Operating mode 27 Operating mode 11 allows cyclic operation (ON/OFF and During the controller enable procedure, the actuator IC 40 OFF/Low/High/OFF). can be adjusted infinitely between the positions for maxi- mum and minimum capacity using its analogue input (termi- The actuator IC moves to the “High fire”...
  • Page 108 Parameter Fault In the event of a fault, there will be no signal at terminals 65 and 66 so that the actuator moves to the closed posi- tion. When approaching the closed position, no timeout of 250 s is active since no feedback input is checked. This BCU 460/LM..F3 may result in a situation where the program is continued in the case of a request for the closed position, without the...

  • Page 109: Function Of Terminal 64

    Parameter 10 . 1 2 .3 Function of terminal 64 Parameter I040 Terminal 64 can be assigned a function using parameter I040 depending on the power module LM..F1 or LM..F3. Al- ternatively, the output can be actuated using a bus system. Parameter I040 = 0: Off.

  • Page 110: Functions Of Contacts 80 To 97

    Parameter 10 . 1 3 Functions of contacts 80 to 97 For a description and the parameter values, see page 110 (Contact 80, 81/82 function). Contacts 80 to 97 are floating contacts. They can be pa- rameterized for various signalling functions. The contacts 10 .

  • Page 111: Functions Of Inputs At Terminals 1 To 7 And 35 To 41

    Parameter 10 . 1 4 Functions of inputs at terminals 1 to 7 Parameter I061 = 8: air actuator R2. The BCU receives the feedback signal for the High position from actuator IC 40 and 35 to 41 through the input. The BCU has multiple physical and logical interfaces to Parameter I061 = 9: start 1.

  • Page 112: Function Of Input 3

    Parameter For parameter values and descriptions, see page 111 10 . 1 4 .8 Function of input 35 (Function of input 1). Parameter I068 To define the input signal for terminal 35. 10 . 1 4 .3 Function of input 3 On a BCU..E1 (power supply via L1), this input should be re- Parameter I063 served for the safety interlock signal (I068 = 4).

  • Page 113: Function Of Input 38

    Parameter 10 . 1 4 . 1 1 Function of input 38 Parameter I071 To define the input signal for terminal 38. A sensor may be connected to this input (I071 = 1, 2 or 3) if necessary. Parameter I071 = 1: sensor 1 Parameter I071 = 2: sensor 2 Parameter I071 = 3: sensor 3 For all other parameter values and descriptions, see page...

  • Page 114: Replacement Possibilities

    Replacement possibilities 11 Replacement possibilities By comparison to the previous generation, the next-gen- eration BCU 4 (2019) units feature new technologies and Burner control units BCU 460 and BCU 465 can be re- functions which can be freely parameterized. placed by the next-generation devices BCU 460 and BCU 465 (2019).
  • Page 115 Replacement possibilities Code Description of BCU (previous generation) Description of BCU Code • S2–3 Number of start-up attempts Can be adjusted using parameter A007: 1, 2 or 3 Pressure switches: none Air flow monitoring air pressure switches POC switch feedback gas pressure switches air and gas pressure switches Preparation for UV sensor for continuous opera-...

  • Page 116: Selection

    Selection 12 Selection 12 . 1 Burner control unit BCU Option Series Mains voltage Q, W Q, W Ignition transformer 1, 2, 3, 8 1, 2, 3, 8 P0, P1, P2, P0, P1, P2, Flange plate P3, P6, P7 P3, P6, P7 Valve proving system C0, C1, C2 C0, C1, C2...

  • Page 117: Type Code

    Selection 12 . 1 . 1 Type code Input function: auxiliary gas and LDS Burner control unit No pressure switches Series 400 Air pressure switches Standard version Gas pressure switches Extended air control Pressure switches for gas and air Version for pilot and main burners No connection plugs Mains voltage: 120 V AC, 50/60 Hz...

  • Page 118: Power Module Lm 400

    Selection 12 .2 Power module LM 400 Option Series Mains voltage Q, W Air actuator F0, F1, F3 Optional output O0, O1, O2 Energy supply E0, E1 Connection plugs K0, K1, K2 Order example LM 400WF1O0E1K1 12 .2 . 1 Type code Power module Series 400 Mains voltage: 120 V AC, 50/60 Hz...

  • Page 119: Project Planning Information

    Project planning information 13 Project planning information 13 . 1 Installation Installation position: vertical (cable glands pointing down- wards) or down flat. 8888 For other mounting options using a fastening set or external securing bars, see page 124 (Fastening set) or page 124 Distance between BCU and burner: recommended < 1 m (External securing bars).

  • Page 120: Electrical Connection

    Project planning information 13 .3 Electrical connection tion or bending) as well as short-circuits, short-circuits to ground and cross-circuits. The BCU is designed for connection to a 1-phase system. All inputs and outputs have a one-phase mains supply. Other connected burner control units must use the same phase of the mains supply.

  • Page 121: Actuators

    Project planning information 13 .4 Actuators 13 .7 Overload protection If actuators are used, the start gas rate of the burners must To protect the unit against overload by frequent cycling, only be limited for SIL 3 applications in compliance with the a specific number of start-up attempts can be carried out standard.

  • Page 122: Calculating The Safety Time T Sa

    Project planning information 13 .8 Calculating the safety time t See www.adlatus.org BCU 460, BCU 465 · 06.20 · EN...

  • Page 123: Accessories

    Accessories 14 Accessories 14 .3 . 1 Opto-adapter PCO 200 14 . 1 High-voltage cable FZLSi 1/7 -50°C (-58°F) to +180°C (+356°F), Order No.: 04250410, FZLK 1/7 -5°C (23°F) to +80°C (176°F), Order No.: 04250409. 14 .2 Industrial plug connector, 16-pin Including BCSoft CD-ROM, Order No.: 74960625.

  • Page 124: Set Of Language Stickers

    Accessories 14 .5 Set of language stickers 14 .7 External securing bars To affix to the cover, with program step/fault message de- The external securing bars are screwed on from inside the scriptions in English, French, Dutch, Spanish and Italian, unit.

  • Page 125: Bus Module Bcm 400

    Accessories 14 .8 Bus module BCM 400 Bus module Bus system Order No . BCM 400S0B1/1-0 PROFIBUS 74960690 Communication interface for connecting the BCU to an au- BCM 400S0B2/3-0 PROFINET 74960691 tomation system. BCM 400S0B3/3-0 EtherNet/IP 74960692 BCM 400..B1 BCM 400..B2, BCM 400..B3 BCU 460, BCU 465 ·...

  • Page 126: Flange Plates

    Accessories 14 .9 Flange plates Order No . Version Description 1 x M32, 6 x M20, 2 x M16 ca- For improved cable routing to ensure simple installation/re- 74960707 (BCU..P2) ble glands moval of the BCU. Depending on the version, also with pre- 16-pin plug, 1 x 16-pin industrial plug, 2 x wired connection plugs for PROFIBUS or 16-pin industrial...

  • Page 127: Bcm 400..B1 Or Bcm 400..B2/B3 At Www.docuthek.com

    BCM 400 15 BCM 400 15 .3 Electrical connection For further information on the electrical connection, com- Use only cable and plug components which comply with missioning and installation, see operating instructions for the relevant PROFIBUS, PROFINET or EtherNet/IP specifi- BCM 400..B1 or BCM 400..B2/B3 at www.docuthek.com.
  • Page 128 BCM 400 Installation guidelines For PROFIBUS, PROFINET, see www.profibus.com, for Ethernet, see www.odva.org. Data cables A and B must not be reversed. BCM..B1/1 PROFIBUS DP Connect the shield on both sides and over a wide area with shield clips in the plug. Switch on the terminal resistors on the first and last sub- scriber in the segment.

  • Page 129: Commissioning

    BCM 400 15 .4 Commissioning BCU . .B2: all the device-specific parameters for the control unit (BCU) are saved in the device master data file (GSD). BCM . .B1 Download from www.docuthek.com. Fieldbus communication can be configured using the engi- BCU . .B3: all the device-specific parameters for the control neering tool of the automation system.

  • Page 130: Installation

    BCM 400 15 .5 Installation 15 .7 Technical data Insert the bus module in the slot provided and set parame- Electrical data ter A080. Power consumption: 1.2 VA. Power loss: 0.7 W. Mechanical data Dimensions (W × H × D): 96 × 63 × 23 mm (3.78 × 2.48 × 0.91 inches). Weight: 0.3 kg.

  • Page 131: Technical Data

    Technical data 16 Technical data Signalling contact for operating and fault signals: max. 1 A at cos φ = 1(external fuse required). Number of operating cycles: The fail-safe outputs (valve 16 . 1 Electrical data outputs V1, V2, V3 and V4) and the air valve output are Mains voltage: monitored for correct functioning and are thus not subject BCU..Q: 120 V AC, -15/+10%, 50/60 Hz, ±5%,...

  • Page 132: Mechanical Data

    Technical data Ignition transformer nominal cross-section 2 x 1.5 mm², wire cross-section min. 0.2 mm², Burner Ignition trans- wire cross-section AWG min. 24, control former Input Output unit (material No .) wire cross-section AWG max. 16, wire cross-section max. 1.5 mm². V AC TRS515PCISOH2 BCU..W1 5000 16 .3 Ambient conditions (34340585)

  • Page 133: Dimensions

    Technical data 16 .4 Dimensions BCU 460, BCU 465 · 06.20 · EN...

  • Page 134: Converting Units

    Converting units 17 Converting units See www.adlatus.org BCU 460, BCU 465 · 06.20 · EN...

  • Page 135: Safety-Specific Characteristic Values For Sil

    Safety-specific characteristic values for SIL and PL 18 Safety-specific characteristic K-SafetyLink 1.0 × 10 Safety interlocks (limits) 2.2 × 10 values for SIL and PL 12.9 × 10 Valve check with redundant pressure switch Certificates – see www.docuthek.com. Air pressure switch monitoring with red. pres- For systems up to SIL 3 pursuant to EN 61508.

  • Page 136: General

    Safety information in accordance with EN 61508-2 19 Safety information in accordance 19 .2 Interfaces with EN 61508-2 Electrical wiring Type of wiring: 19 . 1 General Attachment type X to EN 60730-1. Grounding: via PE wire connection. Scope of application Internal voltages are neither SELV nor PELV. Floating con- as set out in “Industrial thermoprocessing equipment –...

  • Page 137: And Pl

    Safety information in accordance with EN 61508-2 The setting and assignment of the addresses must be veri- fied before commissioning using the verification procedure described in the extended documentation. 19 .4 SIL and PL SIL Safety Integrity Level/PL Performance Level See page 135 (Safety-specific characteristic values for SIL and PL).

  • Page 138: Maintenance

    Maintenance 20 Maintenance Maintenance The fail-safe outputs (valve outputs V1, V2, V3 and V4) of the power module are monitored for correct functioning. In the event of a fault, the system is set to a safe status using a second shut-down path (isolation of the valve outputs from the mains).

  • Page 139: Legend

    Legend 21 Legend Symbol Description Differential pressure switch Symbol Description Ready for operation Actuator with butterfly valve Safety interlocks (limits) Valve with proof of closure switch Control element position check Controlled air flow Remote reset Three-point step switch Safety limits (limits during start-up) Input/Output, safety circuit Gas valve Tightness control...

  • Page 140: Glossary

    Glossary 22 Glossary 22 .4 Safety time during operation t 22 . 1 Waiting time t In standby, the waiting time t starts to elapse in the back- ground. During this time, a self-test is conducted to detect errors in internal and external circuit components. The burner will not be started during the waiting time.

  • Page 141: Safety Shut-Down

    Glossary 22 .6 Safety shut-down blinks and shows the corresponding warning message. The warning signal ends once the cause has been eliminated. The burner control unit performs a safety shut-down imme- The program sequence continues. No safety shut-down or diately after receiving a signal from a safety device or after a fault lock-out occurs.

  • Page 142: Lifting

    Glossary 22 . 1 0 Lifting age could exist for sensors and/or logic system and/or final elements. Unit: % After positioning the actuator IC 20, the BCU checks by see EN ISO 13849-1 means of brief lifting whether its feedback input (termi- nals 40 and 41) has been activated by the correct output 22 .

  • Page 143: Mean Time To Dangerous Failure Mttf

    Glossary 22 . 1 6 Mean time to dangerous failure MTTF Expectation of the mean time to dangerous failure see EN ISO 13849-1:2008 BCU 460, BCU 465 · 06.20 · EN...
  • Page 144 Fore more information The Honeywell Thermal Solutions family of products includes Honeywell Combustion Safety, Eclipse, Exothermics, Hauck, Kromschröder and Maxon. To learn more about our products, visit ThermalSolutions.honey- well.com or contact your Honeywell Sales Engineer. Elster GmbH © 2020 Elster GmbH...

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